Friction stabilizer with tabs

ABSTRACT

A friction stabilizer having tabs comprising a tubular body comprising an exterior surface and having a first portion and having a second portion provided with a taper. The first portion has an impact end and the second portion has an insertion end. A tab is on the tubular body and extends outward from the exterior surface of the tubular body in a direction toward the impact end and away from the insertion end of the tubular body. The tabs can be rectangular shaped or triangular shaped or have other shapes which prevent the friction stabilizer from being removed from a drilled bore in a mine. When the friction stabilizer with tabs is inserted into a drilled bore in a mine, the tabs do not impede insertion. But, after insertion into the drilled bore the tabs resist removal of the tubular body, and thus allow the stabilizer to support the mine wall or ceiling. The friction stabilizer is made by taking a steel coil and punching the shape of the tabs in the metal, for example sheet metal, unrolled from the coil. A notch is also punched into the sheet at a predetermined location. Rolling die roll the tubular body, and a cutting machine cuts the tubular body at the notches, so tubular bodies of predetermined length are cut. The tabs extend from the exterior surface of the tubular body due to the natural spring constant of the steel or metal from which the tubular body is made. A weld ring is welded to the impact end and has a weld ring gap space. In another embodiment the tubular body has first portion, a second portion with a bent portion joining them together. An extendable tab is formed in the first portion proximal the bend portion and the extendable tab is diametrically opposite a tube gap space.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation in part application of U.S. patentapplication Ser. No. 10/946,468, filed on Sep. 21, 2004 to Valgora, fora “Friction Stabilizer With Tabs” the disclose of which is herebyincorporated by reference, which application claims the benefit ofProvisional U.S. Patent Application No. 60/507,366 to Valgora, and filedon Sep. 30, 2003, for a “Friction Stabilizer With Tabs” the disclosureof which is hereby incorporated by reference.

BACKGROUND

Cave-ins are a constant threat associated with underground miningoperations. It is difficult to predict when and where a cave-in willoccur. Typically, workers are provided with little or no warning priorto a cave-in, and thus they have a minimal amount of time to react to acave-in. Indeed, mine walls or ceilings that appear fine upon visualinspection may have significant fractures just below their surfaces,making them structurally weak and prone to collapse. Cave-ins are verydestructive and may result in miners becoming trapped and/or injured.Additionally, equipment and machinery may be damaged or destroyed.

Friction type stabilizers have been used in mining operations tostabilize walls and ceilings of the mine. Such stabilizers are poundedinto bores drilled in mine walls and ceilings. The stabilizers form afriction fit with the drilled bore. But, these stabilizers may slide outof the drilled bores when the rock wall or ceiling shifts/moves, and insuch situations the stabilizers are unable to prevent a mine wall orceiling cave-in.

Therefore, it would be desirable to provide a new and improvedstabilizer that decreases the likelihood of a cave-in. It would also bedesirable if the stabilizer was compatible with existing miningequipment and inexpensive to fabricate.

SUMMARY

The friction stabilizer with tabs according to this invention is used tosecure the walls and ceilings of mines to thus prevent a cave-in fromoccurring. The friction stabilizer with tabs comprises a hollow body,preferably tubular. The tubular body comprises an impact end, aninsertion end, a first portion and a second portion. The second portionhas a notch and is tapered.

The tubular body has an interior and an exterior surface, and tabs areconnected to and extend from the tubular body. The tabs extend in adirection leading away from the insertion end of the tubular body and ina direction leading towards the impact end of the tubular body. The tabseach make an acute angle with the exterior surface of the tubular body.The tabs can be rectangular shaped and there can be three such tabsextending from the exterior surface of the tubular body. Eachrectangular shaped tab further comprises parallel tab side edges and atab free edge connecting between the tab side edges.

In other embodiments, the tabs may be triangular shaped tabs, curvedshaped tabs, polygonal shaped tabs, U-shaped tabs, tabs having bothcurved portions and linear portions, semi-circular shaped tabs, hookshaped tabs, parabolic shaped tabs, and combinations of the above. Also,the tabs can be of any shape that inhibits the withdrawal of thefriction stabilizer with tabs from the drilled bore in a mine. Theabove-described tabs are punched into the sheet from which the tubularbody is formed by a punching machine, thus they are joined to thetubular body at bends.

The tubular body further comprises a first gap space wall and a secondgap space wall spaced apart from one another by a tube gap space. Thetube gap space is used for allowing the tubular body to be compressedradially inward when the tubular body is driven into a drilled bore in amine having, the drilled bore having a diameter less than the outerdiameter of the tubular body.

The friction stabilizer further comprises a weld ring having a weld ringgap space, and the weld ring is joined to the tubular body such that theweld ring gap space and tube gap space are aligned. The weld ring isjoined to the exterior surface of the first portion of the tubular bodyat the impact end of the tubular body by, for example, a weld. The weldring gap space is used for allowing the weld ring to be compressedradially inward. The weld ring can have a rectangular cross section or acircular cross section.

In another embodiment, a friction stabilizer for installation in astructural body is provided. The friction stabilizer has a tubular bodycomprising a first portion a bent portion and a second portion with andthe bent portion joining the first portion and second portion. The firstportion has an extendable tab and a joining portion joins the extendabletab and the tubular body such that the extendable tab is proximal thebent portion. The friction stabilizer also has a tube gap space and anopening diametrically opposite the tube gap space, such that theextendable tab extends from the joining portion into the opening. Theextendable tab is diametrically opposite the tube gap space.

The tubular body is movable from an uncompressed position to acompressed position, such that when in the tubular body is in theuncompressed position the extendable tab is partly positioned in theopening. The tubular body also has an exterior surface and when in theuncompressed position the extendable tab is elevated a minimal amountrelative to the surrounding exterior surface of the tubular body. Theextendable tab extends outward from the tubular body when the tubularbody is in the compressed position, for example when hammered into adrilled bore.

The friction stabilizer includes an insertion end and an opposed impactend with a weld ring having a weld ring gap space joined to the impactend, such that the weld ring gap space is diametrically opposite thetube gap space. The extendable tab extends in a direction toward theimpact end and away from the insertion end. The friction stabilizer canhave another extendable tab proximal the extendable tab and positioneddiametrically opposite the tube gap space. The extendable tab can berectangular or have any suitable geometric shape.

Either embodiment of the friction stabilizer is made by similarprocesses. The process begins by providing a coil of metal and unrollingthe coil of metal into a strip, followed by pressing the shape of thetab or extendable tab to be formed into the strip of metal. The strip ismoved through cold rolling dies, and in one embodiment the strip isrolled into a tubular body having a tube gap space such that the tabsextend from the tubular body. In the other embodiment the strip isrolled into a tubular body having a tube gap space and an exteriorsurface such that the extendable tab is elevated a minimal amountrelative to the exterior surface and is diametrically opposite the tubegap space. The method also includes providing a weld ring having a weldring gap space and welding the weld ring to the impact end of thetubular body.

To use the friction stabilizer with tabs, a drilled bore is made in thewall or ceiling of the mine. The wall is sufficiently solid and ofsufficient thickness to accommodate a bore of sufficient length, and thedrilled bore has a diameter slightly less than the diameter of thetubular body. A support plate having an opening is provided, the openingbeing sized such that the tubular body can pass through the opening. Theopening in the plate is aligned with the drilled bore. The tapered endof the tubular body is aligned with and inserted through the opening inthe plate and into the drilled bore so that the taper of the tubularbody is received in the drilled bore.

Then a pneumatic or hydraulic hammer or some other means for hammeringis used for pounding or driving the stabilizer with tabs into thedrilled bore. As the stabilizer with tabs is driven into the drilledbore the tabs move or flex inwardly towards the exterior surface of thetubular body. This allows the friction stabilizer with tabs to behammered into the drilled bore without the tabs impeding movement.During the pounding process the plate becomes trapped between the weldring and the surrounding ceiling or wall of the mine, as the case maybe. Additionally, the tubular body compresses and the gap space distancedecreases as the friction stabilizer is driven into the drilled bore.Then, if loading force is applied to remove the tubular body with tabs,the tabs immediately dig into the surrounding wall which surrounds thedrilled bore, making the removal of the tubular body significantly moredifficult. Such loading force may come from the plate that is providingsupport. Thus, if the ceiling or wall begins to cave-in, the tabs willkeep digging into the surrounding wall, and the friction stabilizerhaving tabs continues to work against a cave-in. This digging-in actioncould stop a cave-in in progress or limit the severity of a cave-in.Additionally, the digging-in action could provide miners with extra timeto get out of harms way, or provide inspectors with time so that theycan conduct an on site inspection.

The use of the friction stabilizer having the extendable tab is the samethe friction stabilizer is hammered into a drilled bore. However, as thefriction stabilizer is hammered into the drilled bore, it moves from anuncompressed position to a compressed position. As this occurs, theextendable tab moves away from the exterior surface of the tubular bodyand extends outward and into the surrounding drilled bore. Theextendable tab is positioned deep in the drilled bore after hammering,which advantageously provides the friction stabilizer with increasedaxial load carrying capacity.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is an elevational view of the friction stabilizer having tabs.

FIG. 2 is a side elevational view of the friction stabilizer havingtabs.

FIG. 3 is a bottom plan view of the friction stabilizer having tabs.

FIG. 4 is a top plan view of the friction stabilizer having tabs.

FIG. 5 is a sectional view of the friction stabilizer having tabs takenalong cut line 5-5.

FIG. 6 is a sectional view of the friction stabilizer having tabs takenalong cut line 6-6.

FIG. 7 is a top plan view of the strip of steel used to manufacture thefriction stabilizer having tabs.

FIG. 8 shows a bottom plan view of a second embodiment of the frictionstabilizer with rectangular tabs according to a second embodiment of theinvention.

FIG. 9 shows a side elevational view of the second embodiment of thefriction stabilizer with rectangular tabs.

FIG. 10 shows a top plan view of the second embodiment of the frictionstabilizer with rectangular tabs.

FIG. 11 shows a sectional view of the second embodiment of the frictionstabilizer with rectangular tabs taken along cut line 11-11 in FIG. 10.

FIG. 12 shows a sectional view of the second embodiment of the frictionstabilizer with rectangular tabs taken along cut line 12-12 in FIG. 8.

FIG. 13 shows a bottom plan view of a third embodiment of the frictionstabilizer with tabs.

FIG. 14 shows a side elevational view of the third embodiment of thefriction stabilizer with tabs.

FIG. 15 shows a top plan view of the third embodiment of the frictionstabilizer with tabs.

FIG. 16 shows a sectional view of a third embodiment of the frictionstabilizer with tabs taken along cut line 16-16 in FIG. 15.

FIG. 17 shows a sectional view of the third embodiment of the frictionstabilizer with tabs taken along cut line 17-17 in FIG. 13.

FIG. 18 shows a bottom plan view of a fourth embodiment of the frictionstabilizer with tabs.

FIG. 19 shows a side elevational view of the fourth embodiment of thefriction stabilizer with tabs.

FIG. 20 shows a top plan view of the fourth embodiment of the frictionstabilizer with tabs.

FIG. 21 shows a sectional view of the fourth embodiment of the frictionstabilizer with tabs taken along cut line 21-21 in FIG. 20.

FIG. 22 shows a sectional view of the fourth embodiment of the frictionstabilizer with tabs taken along cut line 22-22 in FIG. 18.

FIG. 23 shows a bottom plan view of a fifth embodiment of the frictionstabilizer with tabs.

FIG. 24 shows a side elevational view of the fifth embodiment of thefriction stabilizer with tabs.

FIG. 25 shows a top plan view of the fifth embodiment of the frictionstabilizer with tabs.

FIG. 26 shows a cross sectional view of the fifth embodiment of thefriction stabilizer with tabs taken along cut line 26-26 in FIG. 25.

FIG. 27 shows a cross sectional view of the fifth embodiment of thefriction stabilizer with tabs taken along cut line 27-27 in FIG. 23.

FIG. 27A shows a top plan view of a of a sixth embodiment of thefriction stabilizer with tabs having a plurality of differently shapedtabs.

FIG. 28 is a diagrammatic view of the manufacturing process used formanufacturing the friction stabilizer with tabs.

FIG. 29 is a top plan view of the weld ring having a circular shapedcross section.

FIG. 30 is a sectional view taken along cut line 30-30 in FIG. 29 of theweld ring having a circular shaped cross section.

FIG. 30 a is a view, partly in section, of the circular weld ring andtubular body joined together with a weld.

FIG. 31 is a top plan view of the weld ring having a rectangular shapedcross section.

FIG. 32 is a sectional view taken along cut line 32-32 in FIG. 31 of theweld ring having a rectangular shaped cross section.

FIG. 32 a is a view, partly in section, of the rectangular weld ring andtubular body joined together with a weld.

FIG. 33 is a top plan view of the planar plate.

FIG. 34 is a sectional view of the planar plate taken along cut line34-34 in FIG. 33.

FIG. 35 is a top plan view of the domed plate.

FIG. 36 is a sectional view of the domed plate taken along cut line36-36 in FIG. 35.

FIG. 37 is a sectional view of a mine showing friction stabilizershaving tabs deployed in the mine.

FIG. 38 is a bottom plan view of a seventh embodiment of the frictionstabilizer having an extendable tab.

FIG. 39 is a front elevational view of the of the seventh embodiment ofthe friction stabilizer having the extendable tab.

FIG. 40 is a top plan view of the seventh embodiment of the frictionstabilizer having the extendable tab.

FIG. 41 is a is a sectional view of the seventh embodiment taken alongcut line cut line 41-41 as shown in FIG. 40.

FIG. 42 is a sectional view of the seventh embodiment taken alongcut-line 42-42 as shown in FIG. 38.

FIG. 43 is a sectional view of a mine showing the friction stabilizerhaving the extendable tab.

FIG. 44 shows an enlarged view, partly in section, of FIG. 43.

FIG. 45 is a diagrammatic view of the manufacturing process used formanufacturing the friction stabilizer with extendable tabs.

DESCRIPTION

At the outset, it noted that like reference numbers are intended toidentify the same structure, portions, or surfaces consistentlythroughout the figures. It is also noted that when the term “about” isused in connection with describing a number that the number includesnumbers in decimal form that can be rounded to that number.

Shown generally in FIGS. 1-6 is the friction stabilizer 20 with tabs 25.FIG. 4 shows a top plan view of the friction stabilizer with tabs 20. Asshown in FIGS. 1 and 3, the friction stabilizer with tabs 20 comprises atubular body 22 having tabs 25 extending therefrom. The tubular body 22is elongate and has a first portion 33 and a second portion 34. Thesecond portion 34 is formed integral joined to the first portion 33, andthe second portion 34 has a taper 35. The tubular body 22 has an impactend 30 and an insertion end 32 that are spaced from one another by thelength, designated L in FIG. 4, of the tubular body 22. The taper 34extends from the insertion end 32 in a direction toward the impact end30, until it reaches the first portion 33. The tubular body 22 maycomprise a total length L of about sixty inches, about four inches ofwhich comprise the second portion 34 having the taper 35.

The tubular body 22 further comprises an interior surface 24 and anexterior surface 26, as shown in FIGS. 3 and 5. The interior surface 24defines a stabilizer interior 23 internal to the tubular body 22.

As further shown in FIGS. 3 and 5, the tubular body 22 has a first gapspace wall 27 and a second gap space wall 29 which are spaced apart fromone another. The first and second gap space walls 27, 29, respectively,extend along the length L of the tubular body 22, from the impact end 30of the tubular body 22 to the insertion end 32 of the tubular body 22.The first and second gap space walls, 27, 29, respectively, define atube gap space 28 between them, that extends in the direction of the ofthe longitudinal axis, designate X in FIG. 2, of the tubular body 22. Asshown in FIGS. 3 and 5, the tube gap space 28 extends along the length Lof the body 22, from the impact end 30 to the insertion end 32 of thetubular body 22. The tube gap space 28 defined between the first andsecond gap space walls 27, 29 is used for allowing tubular body 22 to becompressed radially inward. In a manner to be described presently, thediameter designated D in FIG. 5, of the tubular body 22 decreases whenthe tubular body 22 is driven into a drilled bore 50 formed in a wall 52or ceiling 54 of a mine 56, as shown in FIG. 37. The drilled bore 50 hasa bore diameter 51, designated B in FIG. 37, that is less than thediameter D of the tubular body 22.

A notch 36 is defined in the taper 35 of the second portion 34 of thetubular body 22. The notch 36 allows the taper 35 to be formed in thetubular body 22 at the insertion end 32 thereof when the tubular body 22is being rolled. The taper 35 is used for allowing the insertion end 32of the tubular body 22 to be initially fitted or inserted into thedrilled bore 50. After the taper 35 is fitted into the drilled bore 50,the impact end 30 of the tubular body 22 can be pounded causing thetubular body 22 to move into the drilled bore 50.

In accordance with the invention, the tubular body 20 comprises tabs 25that extend from the exterior surface 26 in a direction toward theimpact end 30 of the tubular body 20, and away from the insertion end 32of the tubular body 22. The tabs 25 work against the removal of thetubular body 22 from a drilled bore 50 in a mine 56. As a result, thetabs 25 advantageously decrease the likelihood of a mine 56 cave-in, aswill be described presently.

In a preferred embodiment, the tabs 25 are embodied to be rectangularshaped tabs 40. In particular, there is a first rectangular shaped tab40 a, a second rectangular shaped tab 40 b, and a third rectangularshaped tab 40 c. The first rectangular shaped tab 40 is positionedclosest to the insertion end 32 of the tubular body 22, and the thirdrectangular shaped tab 40 c is positioned farthest from the insertionend 32 of the tubular body 22, as shown in FIG. 4. The secondrectangular shaped tab 40 b is positioned between the first and secondrectangular shaped tabs 40 a, 40 c, respectively. The first, second, andthird rectangular shaped tabs 40 a, 40 b, and 40 c respectively, arepunched out of, laser cut, or otherwise formed in the tubular body 22,in a method to be described presently.

The first, second, and third rectangular shaped tabs 40 a, 40 b, and 40c, respectively, extend outward from the exterior surface 26 of thetubular body 22. Each rectangular shaped tab 40 a, 40 b, 40 c comprisestwo parallel tab side edges 43 and a tab free edge 45 that extendsbetween the tab side edges 43, as shown in FIG. 7, which is a top planview of the flat strip of metal 102 from which the tubular body 22 isformed. The tab side edges 43 and tab free edges 45 are shown in FIGS.1, 6, and 7. It is noted that the tabs 40 a, 40 b, and 40 c shownthroughout FIGS. 1-6 are structurally the same.

Each of the rectangular shaped tabs 40 a, 40 b, and 40 c, respectively,is joined to the tubular body 22 along a bend 44, with the bend beingopposite the tab free edge 45. The bends 44 are closer to the insertionend 32 of the tubular body 22 than the tab free edge 45. Each of therectangular shaped tabs 40 a, 40 b, and 40 c, respectively, makes anacute angle with the exterior surface 26 of the tubular body 22, asshown in FIG. 2. Also, the rectangular shaped tabs 40 a, 40 b, and 40 c,respectively, extend in a direction leading away from the insertion end32 of the tubular body 22, 30 and in a direction leading toward theimpact end 30 of the tubular body 22, as shown in FIG. 2. Therectangular shaped tabs 40 a, 40 b, and 40 c, respectively, are spacedapart from one another along the tubular body 22, and are formed in thetubular body 22 such that they are opposite to the tube gap space 28, asshown in FIG. 6. It is further noted that there are openings 48, asshown in FIG. 2, in the tubular body 22 under the rectangular shapedtabs 40 a, 40 b, and 40 c, respectively, where they extend from theexterior surface 26.

Then, when the tubular body 22 is pounded into a drilled bore 50insertion end 32 first, the rectangular shaped tabs 40 a, 40 b, and 40c, respectively, bend inward along their bends 44 in a direction towardthe openings 48 in the tubular body 22. In other words, the rectangularshaped tabs 40 a, 40 b, and 40 c, respectively, move back into thetubular body 22 from which they were punched, and thus they do notimpede the tubular body 22 from being pounded into the drilled bore 50in the wall 52 or ceiling 54 of the mine 56, as shown in FIG. 37. Then,in the event of a mine cave-in or wall collapse, the tubular body 22advantageously remains in place and supports the mine wall 52 or ceiling54, since the rectangular shaped tabs 40 a, 40 b, and 40 c,respectively, resist removal from the drilled bore 50 and dig into thesurrounding rock. This is due to the fact that the natural springconstant of the first, second, and third rectangular shaped tabs 40 a,40 b, 40 c, respectively, forces them to dig into the drilled bore 50.

The three rectangular shaped tabs 40 a, 40 b, and 40 c, respectively,are spaced along a tubular body 22 about sixty inches long such that thefirst tab 40 a is about four inches from the insertion end 32 of thetubular body 22, the second tab 40 b is about fourteen inches from theinsertion end 32 of the tubular body 22, and the third tab 40 c is abouttwenty-four inches from the insertion end 32 of the tubular body 22. Therectangular shaped tabs 40 a, 40 b, and 40 c, respectively, can be sizedsuch that the tab side edges 43 are about 0.5 inches long, and the tabfree edge 45 is about 1.0 inch. The rectangular shaped tabs 40 a, 40 b,and 40 c, respectively, advantageously provide for a stabilizer 20 that,when installed in a mine, can support greater loads than stabilizershaving smooth exterior surfaces. Of course, the dimensions may differ inother embodiments.

The friction stabilizer 20 further includes a weld ring 31 that in oneembodiment is rectangular shaped, that is, its cross section isrectangular shaped as shown in FIGS. 31, 32, and 32 a. The rectangularshaped weld ring 31 has a weld ring gap space 39 and flat sides 31 a.The rectangular shaped weld ring 31 is positioned around exteriorsurface 26 of the tubular body 22 adjacent to the impact end 30 thereof,as shown in FIGS. 1-4. The weld ring gap space 39 is aligned with thetube gap space 28 defined in the tubular body 22. The rectangular shapedweld ring 31 is welded to the exterior surface 26 of the tubular body22. The weld 49 that joins the tubular body 22 and rectangular shapedweld ring 31 is best shown in FIG. 5. It is noted that the weld ring gapspace 39 and tube gap space 28 allow for the tubular body 22 to becompressed as it is driven into the drilled bore 50 having a borediameter 51 less than the diameter of the tubular body 22. Therectangular shaped weld ring 31 is used for supporting a plate 58 in amanner to be described presently. In another embodiment, the rectangularshaped weld ring 31 and the tubular body 22 can be welded together,without the tube gap space 28 and weld ring gap space 39 being aligned.

FIG. 5 is a sectional view of the tubular body 22 taken along cut line5-5 of FIG. 3, and FIG. 6 is a sectional view of the tubular body 22taken along cut line 6-6 of FIG. 3.

It is noted that a circular shaped weld ring 37 having a circular shapedcross section, as shown in FIGS. 29, 30, and 30 a, can be successfullyused in accordance with the present invention. However, the rectangularshaped weld ring 31 having a rectangular shaped cross sectionadvantageously provides for a higher quality weld. This is due to thefact that a space 38 can form during the welding process under the weld49 that joins the circular shaped weld ring 37 and the exterior surface26 of the tubular body 22, as shown in FIG. 30 a. Additionally, tosuccessfully weld the circular shaped weld ring 37 to the tubular body22, the weld gun must be accurately positioned. However, such accuratepositioning is oftentimes difficult to achieve, because the machinerythat does the welding vibrates excessively. As a result, the majority ofthe weld 49 can end up on the circular shaped weld ring 37 or on theexterior surface 26 of the tubular body 22. Thus, the weld 49 may end upcatching only one of the circular shaped weld ring 37 or exteriorsurface 26 of the tubular body 22, and/or a space 38 may be formed underthe weld 49 as shown in FIG. 30 a.

The rectangular shaped weld ring 31 shown in FIGS. 31, 32, and 32 aadvantageously has flat sides 31 a. As a result there is no space 38between the flat surfaces 31 a rectangular shaped weld ring 31 and theexterior surface 26 of the tubular body 22, since these two surfacesmake direct contact with one another leaving no room for a space 38 toform under the weld 49. Thus, a high quality weld 49 can be made betweenthe flat surfaces 31 a of the rectangular shaped weld ring 31 andexterior surface 26 of the tubular body 22, even in the presence of thevibrations generated by the welding machines.

The above-described invention can be variously embodied. FIGS. 8-12generally show a second embodiment of the friction stabilizer 20 ahaving rectangular shaped tabs 40. The tubular body 22 a of the secondembodiment is substantially the same as the tubular body 22 of the firstembodiment, in that the tubular body 22 a comprises an exterior surface26, first and second gap space walls 27,29, respectively, a tube gapspace 28, an impact end 30, an insertion end 32, a rectangular weld ring31 having a weld ring gap space 39, a first portion 33, and a secondportion 34 having a taper 35 having a notch 36. Each rectangular tab 40of the second embodiment has parallel tab side edges 43 and a tab freeedge 45. The second embodiment comprises a row 128 of rectangular shapedtabs 40 that are joined to the tubular body 22 a at bends 44, and whichare spaced from one another at predetermined spaced intervals,designated I in FIG. 9, along the length L of the tubular body 22 a. Itis noted that the row 128 extends from the side of the tubular body 22 aopposite the tube gap space 28. As shown in FIGS. 8-10, there are fiverectangular shaped tabs 40 in the row 128. Of course, in otherembodiments, the row of tabs 128 may comprise fewer or more than fiverectangular shaped tabs 40.

FIG. 11 is a sectional view of the tubular body of the second embodimenttaken along cut line 11-11 of FIG. 10, and FIG. 12 is a sectional viewof the tubular body of the second embodiment taken along cut line 12-12taken of FIG. 8. The tubular body 22 a can be used for supporting thewalls 52 and ceiling 54 of a mine 56 in the same manner as previouslydescribed in connection with the first embodiment.

FIGS. 13-17 generally show a third embodiment of the friction stabilizer20 b with tabs. In this embodiment, the tubular body 22 b comprisestriangular shaped tabs 41. The tubular body 22 b of the third embodimentis substantially the same as the tubular body 22 of the firstembodiment, in that the tubular body 22 b comprises an exterior surface26, first and second gap space walls 27,29, respectively, a tube gapspace 28, an impact end 30, insertion end 32, a rectangular weld ring 31having a weld ring gap space 39, a first portion 33, and a secondportion 34 having a taper 35 having a notch. Each triangular shaped tab41 of the third embodiment has two edges 46 that meet at a point 47,thus forming a triangle shape. The triangular shaped tabs 41 are joinedto the tubular body 22 b at bends 44, as shown. There is a row 129 oftriangular shaped tabs 41 that extend from the tubular body 22 b atpredetermined spaced intervals, designated I in FIG. 13, along thelength L of the tubular body 22 b. It is noted that the row 128 extendsfrom the side of the tubular body 22 b opposite the tube gap space 28.As shown in FIGS. 13-17, there are five triangular shaped tabs 41 in therow 130. In other embodiments, the row of triangular shaped tabs 130 maycomprise fewer or more than five triangular shaped tabs 41.

FIG. 16 is a sectional view taken along cut line 16-16 of FIG. 15, andFIG. 17 is a sectional view taken along cut line 17-17 of FIG. 13. Thetubular body 22 b can be used in the same manner as described above inconnection with the first embodiment for supporting the walls 52 andceiling 54 of a mine 56.

FIGS. 18-22 generally show a fourth embodiment of the frictionstabilizer 20 c with tabs. In the fourth embodiment, the tubular body 22c comprises a plurality of rows 128 of rectangular shaped tabs 40. Therectangular shaped tabs 40 in each row 128 are spaced from one another,and the rows 128 are spaced about ninety degrees from one another aboutthe exterior surface 26 of the tubular body 22 c, as viewed in sectionalFIGS. 21 and 22. The tubular body 22 c of the fourth embodiment issubstantially the same as the tubular body 22 of the first embodiment,in that the tubular body 22 c comprises an exterior surface 26, firstand second gap space walls 27,29, respectively, a tube gap space 28, animpact end 30, insertion end 32, a rectangular weld ring 31 having aweld ring gap space 39, a first portion 33, and a second portion 34having a taper 35 having a notch. Each rectangular shaped tab 40 of thefourth embodiment is joined to the tubular body 22 c at a bend 44, andextends in a direction toward the weld ring 31. As shown in FIGS. 18-22there are three rows 128 of the rectangular shaped tabs 40, with fiverectangular shaped tabs 40 per row. In other embodiments, there can evenbe more rows 128 of rectangular shaped tabs 40 provided for on thetubular body 22 c, or the number of rectangular shaped tabs 40 in eachrow may be increased or decreased.

FIG. 21 is a sectional view taken along cut line 21-21 of FIG. 20, andFIG. 22 is a sectional view taken along cut line 22-22 of FIG. 18. Thetubular body 22 c can be used in the same manner as described above inconnection with the first embodiment for supporting the walls 52 andceiling 54 of a mine 56.

FIGS. 23-27 generally show a fifth embodiment of the friction stabilizer20 d. In the fifth embodiment, the tubular body 22 d comprises aplurality of rows 130 of triangular shaped tabs 41. The tubular body 22d of the fifth embodiment is substantially the same as the tubular body22 of the third embodiment, in that the tubular body 22 d comprises anexterior surface 26, first and second gap space walls 27,29,respectively, a tube gap space 28, an impact end 30, insertion end 32, arectangular weld ring 31 having a weld ring gap space 39, a firstportion 33, and a second portion 34 having a taper 35 having a notch.Each triangular shaped tab 41 of the fifth embodiment is joined to thetubular body 22 d at a bend 44, and extends away from the tubular body22 d. The edges 46 of each triangular shaped tab 41 meet at a point 47.As shown in FIGS. 23-25 there are three rows 130 of the triangularshaped tabs 41, with five tabs 41 per row 130. The rows 130 oftriangular shaped tabs 41 are spaced about ninety degrees from oneanother about the exterior surface 26 of the tubular body 22 d, asviewed in FIGS. 26 and 27. In yet other embodiments, there can even bemore rows 130 of triangular shaped tabs 41 provided for on the tubularbody 22 d.

FIG. 26 is a sectional view taken along cut line 26-26 of FIG. 25, andFIG. 27 is a sectional view taken along cut line 27-27 of FIG. 23. Thetubular body 22 d can be used in the same manner as described above inconnection with the first embodiment for supporting the walls 52 andceiling 54 of a mine 56.

Shown in FIG. 27A is a sixth embodiment of the friction stabilizer 20 ewherein the tubular body 22 e has a plurality of differently shaped tabs25. The tabs 25 may be curved shaped tabs, rectangular shaped tabs,triangular shaped tabs, polygonal shaped tabs, U-shaped tabs, tabshaving both curved portions and linear portions, semi-circular shapedtabs, hook shaped tabs, parabolic shaped tabs, combinations of theabove, or any other shaped tab that inhibits the withdrawal of thefriction stabilizer 20 e from the drilled bore 50 in the mine 56. Theabove-described tabs 25 may extend in patterns, rows, series, orrandomly from the exterior surface 26 of the friction stabilizer 20 e.As shown in FIG. 27A, a plurality of differently shaped tabs 25, asdescribed above, extend from the friction stabilizer 20 e. In otherembodiments, a single tab 25, for example a rectangular shaped tab 40 ora triangular shaped tab 41, may extend from the exterior surface 26 ofthe friction stabilizer 20. The single tab may be any of the aboveshapes. Thus, the present invention has significant versatility and maybe variously embodied, and all of these embodiments are within the scopeof the present invention.

In a seventh embodiment shown in FIGS. 38-45, there is a frictionstabilizer 20 f having a tubular body 22 f. As shown in FIGS. 38-42, thetubular body 22 f is elongate and has a first portion 33 a bent portion53 and a second portion 34 with the bent portion 53 joining the firstportion 33 and the second portion 34. The tubular body 22 f ispreferably formed as one piece. The first portion 33 has an impact end30 and the second portion 34 has an opposed insertion end 32. The firstportion 33 also has a weld ring 31 joined to it with, for example a weld49, and the weld ring 31 can have a rectangular or circular crosssection. The second portion 34 of the tubular body 22 f has a taper 35,and the taper 35 extends from the insertion end 32 in a direction towardthe impact end 30 until it meets with the bent portion 53.

In addition, the tubular body 22 f includes an interior surface 24 thatis concave and an opposed exterior surface 26 that is convex, as shownin FIGS. 41 and 42. The interior surface 24 defines a stabilizerinterior 23 that is internal to the tubular body 22 f.

As further shown in FIGS. 38, 41 and 42, the tubular body 22 f has afirst gap space wall 27 and a second gap space wall 29 which are spacedapart from one another and face one another. As shown in FIG. 39, thefirst and second gap space walls 27, 29, respectively, extend along thelength of the tubular body 22 f, designated L in FIG. 39, from theimpact end 30 of the tubular body 22 f to the insertion end 32 of thetubular body 22 f. A tube gap space 28 extends from the first gap spacewall 27 to the second gap space wall 29 and the length L of the tubularbody 22 f, from the impact end 30 to the insertion end 32. As shown inFIGS. 40-43, the weld ring 31 has a weld ring gap space 39, and the weldring 31 is welded to the first portion 33 with a weld 49, such that theweld ring gap space 39 is diametrically opposite the tube gap space 28,as shown in FIG. 41.

In addition, the tubular body 22 f is capable of being compressedradially inward because of the tube gap space 28. In a manner to bedescribed presently, the diameter of the tubular body 22 f designated Din FIG. 39 decreases when the tubular body 22 f is hammered into adrilled bore 50 having a smaller diameter, designated B in FIG. 43, aswill be described in greater detail presently.

As shown in FIGS. 38, 39 and 42, a notch 36 is defined in the taper 35of the second portion 34 of the tubular body 22 f. The notch 36 extendsfrom the insertion end 32 partly into the second portion 34 of thetubular body 22 f. The taper 35 of the second portion 34 increases inthe vicinity of the notch 36. Thus, the tube gap space 28 decreases inthe second portion 34 due to the taper 35, and tube gap space 38decreases an additional amount in the vicinity of the notch 36. Thisfacilitates introduction of the tubular body 22 f into the drilled bore50. In addition, the notch 36 allows the taper 35 to be formed in thetubular body 22 f at the insertion end 32 thereof when the tubular body22 f is roll formed. After the taper 35 is fitted into the drilled bore50, the impact end 30 of the tubular body 22 f can be hammered causingthe tubular body 22 f to move into the drilled bore 50.

The tubular body 22 f has a thickness designated TT as shown in FIG. 41which extends from the exterior surface 24 to the opposed interiorsurface 26 of the tubular body 22 f.

As shown in FIGS. 38-40 and 42, the tubular body 22 f has a singleextendable tab 25 b that is joined to the first portion 32 of thetubular body 22 f with a tab joining portion 180. The extendable tab 25b is positioned diametrically opposite the tube gap space 28. Inaddition, and extendable tab 25 b is proximal the bent portion 37. Inparticular, the extendable tab 25 b is positioned such that moving fromright to left in FIGS. 38-40, the insertion end 32 is first encounteredand then the second portion 34 is encountered. Next, the bent portion 53is encountered, and then the first portion 33 is encountered with thetab joining portion 180 and extendable tab 25 b being encounteredimmediately thereafter. Thus, the extendable tab 25 b is proximal thebent portion 53, but not joined to the bend portion 53. In addition, theextendable tab 25 b extends in a direction leading away from theinsertion end 32 of the tubular body 22 f and in a direction leadingtowards the impact end 30 of the tubular body 22 f, as shown in FIGS.38-40.

As previously mentioned, the tubular body 22 f is capable of compressingradially inward, for example when it is hammered into a drilled bore 50having diameter less than that of the tubular body 22 f, as will bedescribed presently. The tube gap space 28 allows for such inward radialcompression of the tubular body 22 f. Thus, the tubular body 22 f iscapable of moving from a non-compressed position 190 (as shown in FIGS.38-42) to a compressed position 192 when hammered into a drilled bore.

As shown in FIGS. 38, 40 and 42, the extendable tab 25 b has an interiortab surface 182 and an opposed exterior tab surface 184, and because theextendable tab 25 b is formed in the tubular body 22 f, it also has athickness designated TT. The tubular body 22 f has an opening 48 inwhich the extendable tab 25 b is partly positioned. In particular, whenthe tubular body 22 f is in the non-compressed position 190 as shown inFIGS. 38-40 and 42, the extendable tab 25 b is partly positioned in theopening 48, and partly elevated with respect to the surrounding exteriorsurface 26 of the tubular body 22 f. As shown in FIGS. 39 and 42, theextendable tab 25 b extends a minimal amount relative to the surroundingexterior surface 26 of the tubular body. Thus, the extendable tab 25 bis bent at the joining portion 180 such that the extendable tab 25 bmakes a makes a minimal angle with respect to the surrounding exteriorsurface 26 of the tubular body 22 f. As shown in FIGS. 39 and 42, whentubular body 22 f is in the non-compressed position 190, the extendabletab 25 b is partly in the opening 48 and partly raised or elevated aminimal amount relative to the surrounding exterior surface 26 of thefirst portion 33, as described above.

When the tubular body 22 f is radially compressed and is moved to thecompressed position 192 (for example when hammered into a drilled bore50 as will be described presently and as shown in FIGS. 43 and 44), theextendable tab 25 b bends at the joining portion 180, and the extendabletab 25 b moves out of the opening 48. The extendable tab 25 b extendsaway from the exterior surface 26 the tubular body 22 f, such that theextendable tab 25 b makes an acute angle with the exterior surface 26 ofthe tubular body 22 f. Thus, the extendable tab 25 b is caused to moveout of the opening 48 when the tubular body 22 f is compressed, and iscapable of moving from a non-extended position 183, as shown in FIGS.38-40 and 42, when the tubular body 22 f is in the non-compressedposition 190, to an extended position 185, as shown in FIGS. 43 and 44,when the tubular body 22 f is in the compressed position 192.

FIGS. 43 and 44 show the friction stabilizer 20 f installed in a drilledbore 50. During installation the insertion end 32 of the tubular body 22f is introduced into the drilled bore 50, and the extendable tab 25 b isin the above-described non-extended position 183. As hammering begins,the tube gap space 28 decreases and the tubular body 22 f begins tocompress radially inward, and the extendable tab 25 b moves out of theopening 48 and moves to the extended position 185 such that it contactsthe drilled bore 50. After hammering, the extendable tab 25 b engagesthe drilled bore thus increasing the axially holding capacity of thefriction stabilizer 20 f.

The extendable tab 25 b positioned diametrically opposite the tube gapspace 28 and proximal the bent portion 37, as described above,advantageously significantly increases the axial load bearing capacityof the tubular body 22 f. Two extendable tabs 25 b each positioneddiametrically opposite the tube gap space 28 and each proximal the bentportion 37 as described above also advantageously significantly increasethe holding capacity or axial load bearing capacity of the frictionstabilizer 20 f. The second extendable tab 25 b is shown in phantomlines in FIG. 40, and as shown, the extendable tabs 25 b are proximal toone another. A third extendable tab 25 b could also be formed in thetubular body 22 f is the same manner as described above and in line withthe other extendable tabs 25 b. In other embodiments there can be morethan three extendable tabs 25 b each positioned diametrically oppositethe tube gap space 28.

The extendable tab 25 f can have any geometry, for example it can berectangular shaped as shown in FIG. 38 a. It can also be triangleshaped, curved, polygonal or virtually any shape that can engage adrilled bore 50.

There are additional advantages associated with the extendable tab 25 b.For example, the tubular body 22 f is safer to handle in the minebecause the extendable tab 25 b is in the non-extended position 183prior to introduction into the drilled bore 50. Thus, there is a reducedlikelihood that mine workers and factory works will be injured by theextendable tab 25 b. Another advantage is that the extendable tab 25 bdoes not extend outward from the surrounding exterior surface 26 of thetubular body 22 f until the tubular body 22 f has been hammered into thedrilled bore 50, thus the friction stabilizers 20 f can be neatlystacked for shipment. Another advantage is the increased axial holdingcapacity of the friction stabilizer 20 f.

To manufacture the friction stabilizer with tabs 20, reference is madeto the schematic shown in FIG. 28. The process or method begins with acoil of metal, preferably steel or a steel alloy 100. First, a planar orflat strip of steel 102 pulled from the steel coil, in the directionindicated by the arrows in FIG. 28. The strip 102 has a width,designated W in FIG. 7, that is about three inches wide in the firstembodiment. In other embodiments, the width could be more than or lessthan three inches, depending on the particular application or customerrequirement.

As the strip of steel 102 is pulled from the coil 100, it moves onto aconveyor 105. The strip of steel 102 passes through a pressing machine104 wherein the tab side edges 43 and tab free edges 45 are pressed intothe flat strip of steel 102. Pressing machines are well known to thosehaving ordinary skill in the art. It is to be understood that the tabside edges 43 and free edges 45 may also be laser cut or otherwiseformed in the sheet of steel 102 at this point in the manufacturingprocess, by the use of a laser or other device. The shape of the tab 25is thus formed in the sheet of steel 102. It is to be further understoodthat any desired shape of the tab 25 could be formed by the pressingmachine 104.

The strip 102 is next moved by conveyor 105 through a punching machine106 where the notches 36 are punched out of or otherwise formed into theflat strip 102. Punching machines 106 are known to those having ordinaryskill in the art. In another embodiment, the notches 36 could be punchedfrom the strip 102 first, and then the tabs 40 pressed in the strip 102.

A means for measuring 108 continuously measures the length of the strip102 prior to the punching machine 106 so that the notch 36 can bepunched in the strip 102 at the desired position in the strip 102. Thefinal length of the friction stabilizer with tabs 20 is thus determinedby the notch 36 location in the strip 102. Next, the strip 102 passesfrom the punching machine 106 and is moved by conveyor 105 through acold roll forming mill 110. The cold roll forming mill 110 comprises aseries of stands having top and bottom rolling die 112 a, 112 b,respectively. Cold roll forming mills 110 are known to those havingordinary skill in the art.

As the strip 102 progresses from stand to stand in the cold rolling mill110 it is formed into a tubular body 22 having the above-described tubegap space 28. At the same time, the rectangular shaped tabs 40 begin tomove away from the exterior surface 26 of the continuous tubular body 22z that is being formed in the cold rolling mill 110. This is attributedto the fact that the natural spring constant of the steel, steel alloy,galvanized steel, or other metal from which the continuous tubular body22 z, is made causes the rectangular shaped tabs 40 to extend from theexterior surface 26 thereof. It is noted that if the tabs do not extendout, then they may be mechanically pushed out of the tubular body 22.

As the continuous tubular body 22 z exits the cold roll forming mill110, the tabs 40 extend from it as previously described and it hasnotches 36, but still has to be cut to the predetermined length. Thecontinuous tubular body 22 z is then moved by conveyor 105 through acut-off press 114, where the notch 36 in the tubular body 22 signals thecut-off press 114 to cut the tubular body 22 to the predetermined lengthat the notch 36. The length of the tubular body may be about 60 inchesas shown in FIG. 1 and described in the first embodiment, but in otherembodiments, the tubular body 22 can be formed to have a length of 18inches, 24 inches, over six feet, or any length required for theparticular job, application, or customer order.

The tubular body 22 is then placed on conveyor 105 and transported to aswaging station 116. At the swaging station 116, the insertion end 32 ofthe tubular body 22, where the notch 36 is located, has pressure appliedto it such that the taper 35 is formed at the insertion end 32. It isnoted that the notch 36 provides the space for the taper 35 to be formedin the section portion 34 in the swaging station 116.

The tubular body 22 is then moved by a conveyor 105 to a welding station118. At the welding station 118 the rectangular shaped weld ring 38 isfitted about the impact end 30 of the tubular body 22, such that theweld ring gap space 39 aligns with the tube gap space 28. In anotherembodiment the weld ring gap space 39 and tube gap space 28 are notaligned. While held in this position by the welding machine, the tubularbody 22 and weld ring 38 are welded together, and thus joined by a weld49. Welding stations 118 are well known to those having ordinary skillin that art. After welding, the weld ring 38 is joined with the impactend 30 of the tubular body 22. The weld ring gap space 39 may be lasercut or punched out of the weld ring 38.

After exiting the welding station 118, the tubular bodies 22 are movedby conveyor 105 to a packing station 120 having an automatic packagingmachine 121. Every other tubular body 22 is then turned end over end andautomatically packaged in bundles 122 of, for example, six tubularbodies 22, by the automatic packaging machine 121. Automatic packagingmachines 121 are known to those having ordinary skill in the art. Thebundles 122 are transported by conveyor 105 to a shipping station 124,placed in crates 126, and shipped.

After the friction stabilizer with tabs 20 has been rolled and formed asdescribed above, the tabs 40 may have sharp tab side edges 43 and tabfree edges 45. Thus, another step that may be included in the process ormethod is a grinding step, which takes place prior to automatic packingof the tubular bodies 22. During the grinding step, any sharp tab sideedges 43 and tab free edges 45 are ground down and dulled, thusdecreasing the likelihood of a worker being cut or injured by the tabs40.

The same general method or process is carried out to make the otherembodiments of the friction stabilizer having tabs 20, described above.For each embodiment the pressing machine 104 would stamp, punch, or cutedges in the strip of steel 102 such that the tab 25 of desired shapemay be formed (rectangular shaped tabs, triangular shaped tabs, curvedshaped tabs, polygonal shaped tabs, U-shaped tabs, tabs having bothcurved portions and linear portions, semi-circular shaped tabs, hookshaped tabs, parabolic shaped tabs, combinations of the above, or anyother shaped tab that inhibits the withdrawal of the friction stabilizerwith tabs 20 from the drilled bore 50 in the mine 56).

To make the friction stabilizer 20 f having the tubular body 20 f withthe extendable tab 25 b, reference is made to the schematic shown inFIG. 45. The process or method begins with a coil of metal, preferablysteel or a steel alloy 100. First, a planar or flat strip of steel 102pulled from the steel coil, in the direction indicated by the arrows inFIG. 45. The strip 102 has a width, designated W in FIG. 7, that isabout three inches wide in the first embodiment. In other embodiments,the width could be more than or less than three inches, depending on theparticular application or customer requirement.

As the strip of steel 102 is pulled from the coil 100, it moves onto aconveyor 105. The strip of steel 102 passes through a pressing machine104 wherein the extendable tab 25 b is pressed, laser cut or otherwisedefined in the flat strip of steel 102. Pressing machines are well knownto those having ordinary skill in the art.

The strip 102 is next moved by conveyor 105 through a punching machine106 where the notches 36 are punched out of or otherwise formed into theflat strip 102. Punching machines 106 are known to those having ordinaryskill in the art. In another embodiment, the notches 36 could be punchedfrom the strip 102 first, and then the tabs 40 pressed in the strip 102.

A means for measuring 108 continuously measures the length of the strip102 prior to the punching machine 106 so that the notch 36 can bepunched in the strip 102 at the desired position in the strip 102. Thefinal length of the friction stabilizer with tabs 20 f is thusdetermined by the notch 36 location in the strip 102.

Next, the strip 102 passes from the punching machine 106 and is moved byconveyor 105 through a cold roll forming mill 111. The cold roll formingmill 111 comprises a series of stands having top and bottom extendabletab rolling die 113 a, 113 b, respectively. As the strip 102 progressesfrom stand to stand in the cold rolling mill 111 it is formed into atubular body 22 f having the above-described tube gap space 28. Duringcold rolling the extendable tab 25 b extends from the strip 102 only aminimal amount from the exterior surface 26 of the continuous tubularbody 22 z that is being formed in the cold rolling mill 111. It ispointed out that this cold rolling is different from the above-describedcold rolling, in that the tubular body 22 f is rolled such that theextendable tab 25 a does not fully extend outward during the coldrolling processes. That is, the cold rolling process is such that itprevents the full extension of the extendable tab 25 b. Rather, theextendable tab 25 b extends only a minimal amount from an exteriorsurface of the continuous tubular body 22 z.

The continuous tubular body 22 z is then moved by conveyor 105 through acut-off press 114, where the notch 36 in the tubular body 22 signals thecut-off press 114 to cut the tubular body 22 f to the predeterminedlength at the notch 36. The length of the tubular body 22 f may be about60 inches as shown in FIG. 1 and described in the first embodiment, butin other embodiments, the tubular body 22 can be formed to have a lengthof 18 inches, 24 inches, over six feet, or any length required for theparticular job, application, or customer order.

The tubular body 22 f is then placed on conveyor 105 and transported toa swaging and ring station 116. At the swaging and ring station 116, theinsertion end 32 of the tubular body 22 f, where the notch 36 islocated, has pressure applied to it such that the taper 35 is formed atthe insertion end 32, and the weld ring is positioned around thecontinuous tubular body 22 z. It is noted that the notch 36 provides thespace for the taper 35 to be formed in the section portion 34 in theswaging station 116.

The tubular body 22 f is then moved by a conveyor 105 to a weldingstation 118. At the welding station 118 the weld ring 38 is fitted aboutthe impact end 30 of the tubular body 22 f, such that the weld ring gapspace 39 is diametrically opposite the tube gap space 28. While held inthis position by the welding machine, the tubular body 22 and weld ring31 are welded together, and thus joined by a weld 49. After welding, theweld ring 38 is joined with the impact end 30 of the tubular body 22.

After exiting the welding station 118, the tubular bodies 22 f are movedby conveyor 105 to a packing station 120 having an automatic packagingmachine 121. Every other tubular body 22 is then turned end over end andautomatically packaged in bundles 122 of, for example, six tubularbodies 22 f, by the automatic packaging machine 121. In addition,because the extendable tab 25 b is not extended, the bundles can beadvantageously readily stacked. Automatic packaging machines 121 areknown to those having ordinary skill in the art. The bundles 122 aretransported by conveyor 105 to a shipping station 124, placed in crates126, and shipped.

To use the friction stabilizer 20 with tabs, a drilled bore 50 is madein a wall 52 or ceiling 54 of a mine 56 having a floor 55, as shown inFIG. 37. It is understood that forming a drilled bore 50 in a mine 56 isknown to those having ordinary skill in the art. The drilled bores 50are made in the 52 ceilings and/or walls 54 of the mine 56. The drilledbore 50 has a diameter, designated B in FIG. 37, which is less than thediameter of the tubular body 22, designated S and shown in FIG. 4.

As shown in FIGS. 33 and 34, a plate 58 having a plate opening 60 isprovided. The plate 58 has planar surfaces 59, and is of metal,preferably steel, steel alloys, stainless steel, and galvanized steel.The plate opening 60 is sized such that the friction stabilizer 22 canbe moved through the opening 60. But, the weld ring 38 is too large topass through the plate opening 60. The plate 58 is positioned such thatthe opening 60 is brought into alignment with the drilled bore 50 thewall 52 or ceiling 54, as the case may be, of the mine 56, and held inthat position. Since the taper 35 at the insertion end 32 of the tubularbody 22 has a diameter less than the diameter, designated B, of thedrilled bore 50, the insertion end 30 of the tubular body 22 can bereadily moved into the drilled bore 50. In particular, the insertion end32 is moved through the opening 60 in the plate 58, such that the taperportion 34 is moved into the drilled bore 50. However, because thediameter, designated S, of the tubular body is greater than thediameter, designated B, of the drilled bore 50, the first portion 33 ofthe tubular body 22 must be driven into the drilled bore 50.

To accomplish this, the impact end 30 of the tubular body 22 is drivenby a pneumatic hammer, hydraulic hammer, or other means for hammering ordriving (not shown) into the drilled bore 50. The tubular body 22compresses radially inward as it is driven into the drilled bore 50,such that the tube gap space 28 decreases.

Additionally, the tabs 40 fold in a direction toward the exteriorsurface 26 of the tubular body 22, and do not resist insertion of thetubular body 22 into the drilled bore 50. As a result of tubular body 22being driven into the lesser diameter drilled bore 50, the tubular body22 compresses radially inward and the tube gap space 28 and weld ringgap space 39 both decrease. The tubular body 50 then exerts expandingforces against the adjacent surrounding drilled bore wall 51.

Also, in another embodiment shown in FIGS. 35 and 36, the plate can be adomed-shaped plate 64 having a domed portion 65. The domed portion 65has an opening 67 for receiving the friction stabilizer 20there-through. Contact surfaces 69 are provided on the domed plate 64and are used for contacting the wall 52 or ceiling 54 of the mine 56.

It is noted that as the stabilizer 20 with tabs is driven into thedrilled bore 50, the rectangular shaped tabs 40 move downwardly towardthe tubular body 22 and do not obstruct insertion into the drilled bore50. However, once driven into the drilled bore 50, the tabs 40 forceoutwardly from the tubular body 22 due to the natural spring constant ofthe steel or other material from which the stabilizer with tabs 20 ismade. The tabs 40 contact the adjacent surrounding drilled bore wall 51and dig into it, resulting in the friction stabilizer with tabs 20 beingheld in the drilled bore 50 by both a friction fit created by theexpanding forces generated by the tubular body 22, and by the tabs 40digging into the drilled bore 50.

Then, if force is applied to remove the friction stabilizer with tabs20, the tabs 40 immediately dig into the adjacent drilled bore wall 51and work against removal of the stabilizer with tabs 20 from the drilledbore 50. This significantly reduces the likelihood that the stabilizerwith tabs 20 will work its way out of the drilled bore 50 andadvantageously significantly increases the amount of weight or force thefriction stabilizer with tabs 20 can support. Thus the frictionstabilizer with tabs 20 advantageously decreases the likelihood of acave-in of walls 52 and/or ceilings 54 of a mine 56.

In addition, the plate 58, which is trapped between the weld ring 38 andmine wall 52 or ceiling 54 after installation, provides for additionalsupport of the surrounding mine walls 52 and ceilings 54, as the casemay be. It is noted that the plate 58 is supported by the weld ring 38.Thus, if the rock above the plate 58 fractures and weakens, the plate 58supports the rock, and the plate 58 in turn is supported by the frictionstabilizer with tabs 20 in the drilled bore 50, and the tabs 40advantageously constantly working against removal of the frictionstabilizer with tabs 20 from the drilled bore 51.

The present invention also provided for a mine support system 80. Inparticular, the friction stabilizer 20 having tabs can be positioned andspaced from one another in drilled bores 50 that are spaced about threefeet apart from one another in all directions, for example in the walls52 and ceiling 54 of the mine 56. A wire mesh 65 is provided. The wiremesh 65 is positioned adjacent to the walls 52 and ceiling 54 of themine 56. Then the plates 58 are aligned with the drilled bores 50 in themanner described above. Next, the friction stabilizer 20 is driven intothe drilled bore 50 in the manner previously described. The wire mesh 65extends between all of the plates 58 in the mine and is trapped betweenthe plates 58 and the mine wall 52 and plates 58 and ceiling 54. Thewire mesh 65 serves to support any rocks or debris that break off of thewalls 52 or ceiling 54 of the mine 56. The ability of the wire mesh 65to support greater loads is advantageously increased, because thefriction stabilizer having tabs 40 can support a greater load from thewire mesh 65. Thus, the stabilizer with tabs 20 can be used as anintegral part of a mine support system 80 to prevent mine 56 cave-ins.

It is noted that the above-described support system 80 can be used incombination with any of the above-described embodiments of the frictionstabilizer having tabs 20.

As previously described, in other embodiments the tabs 25 can be any ofa plurality of different shapes (rectangular shaped tabs, triangularshaped tabs, curved shaped tabs, polygonal shaped tabs, U-shaped tabs,tabs having both curved portions and linear portions, semi-circularshaped tabs, hook shaped tabs, parabolic shaped tabs, combinations ofthe above, or any other shaped tab that inhibits the withdrawal of thefriction stabilizer with tabs 20 from the drilled bore 50 in the mine56).

Additionally, in other embodiments, the rectangular shaped tabs 40 canbe formed such that they extend from the tubular body 22 anywhere fromthe exterior surface 26 of the tubular body 22 including randomly or inpatterns. The same is true with respect to all of the above-describeddifferently shaped tabs 25, in that they may all extend from the tubularbody 22 randomly or in patterns. Also, the number of tabs 25 can bevaried regardless of the shape of the tab 25. In addition, the size ofthe tab 25 can be varied depending on the requirements of the particularapplication in which the stabilizer 20 will be deployed. In yet otherembodiments a single tab 25 having any of the above described shapes mayextend from the tubular body 22. Also, in other embodiments the lengthof the taper 35 of the second portion 34 may be increased or decreased.

With respect to the seventh embodiment, as shown in FIGS. 43 and 44,during the hammering process the tubular body 22 f compresses radiallyinward as it is hammered into the drilled bore 50, and moves from thenon-compressed condition 190 to the compressed condition 192. As thisoccurs, the extendable tab 25 b moves out of the opening 48. Stateddifferently, the extendable tab 25 b extends outward from the tubularbody 22 f as the tubular body 22 f is hammered deeper into the drilledbore 50, and the extendable tab 25 b extends into the surroundingdrilled bore 50. When hammering is complete, the extendable tab 25 badvantageously extends into the drilled bore 50 at a position deepinside the drilled bore 50, advantageously resulting in increased axialholding capacity of the friction stabilizer 20 f which prevents minecollapse.

Also, the diameter of the tubular body 22 of the friction stabilizerwith tabs 20 may be more or less than an inch, but in other embodimentsthe diameter of the stabilizer may be customized to suit particularneeds for a particular application. The tubular body 22 can comprisevarious lengths L, for example the sixty inch length described above, ora length required for a particular application. For example, some mines56 may require tubular bodies 22 having lengths of twelve, eighteen, orforty inches, whereas other mines 56 may require tubular bodies 22having lengths of over two hundred inches. The friction stabilizerhaving tabs 20 may be used in these mining applications. The materialfrom which the stabilizer 20 and weld ring 38 are made comprises metal,such as steel, steel alloys, galvanized steel, high strength steel,metal and metal alloys.

Although a friction stabilizer 20 with tabs has been described, thepresent invention could be otherwise embodied without departing from theprinciples thereof, and all such embodiments come with the scope andsprit of the present invention for a friction stabilizer 20 having tabs.

1. A friction stabilizer for installation in a structural body, thefriction stabilizer comprising: a) a tubular body comprising a firstportion a bent portion and a second portion with and the bent portionjoining the first portion and second portion, c) a joining portion joinsan extendable tab to the first portion such that the extendable tab isproximal the bent portion.
 2. The friction stabilizer according to claim1 wherein the tubular body has a tube gap space and an openingdiametrically opposite the tube gap space and the extendable tab extendsfrom the joining portion into the opening such that the extendable tabis diametrically opposite the tube gap space.
 3. The friction stabilizeraccording to claim 2 wherein the tubular body is movable from anuncompressed position to a compressed position, such that when in thetubular body is in the uncompressed position the extendable tab ispartly positioned in the opening.
 4. The friction stabilizer accordingto claim 2 wherein the tubular body has an exterior surface and thetubular body is movable from an uncompressed position to a compressedposition and when in the uncompressed position the extendable tab iselevated a minimal amount relative to the surrounding exterior surfaceof the tubular body.
 5. The friction stabilizer according to claim 3wherein the extendable tab extends outward from the tubular body whenthe tubular body is in the compressed position.
 6. The frictionstabilizer according to claim 4 wherein the extendable tab extendsoutward from the tubular body when the tubular body is in the compressedposition
 7. The friction stabilizer according to claim 2 furtherincluding an insertion end and an opposed impact end with a weld ringhaving a weld ring gap space joined to the impact end such that the weldring gap space is diametrically opposite the tube gap space.
 8. Thefriction stabilizer according to claim 7 wherein the extendable tabextends in a direction toward the impact end and away from the insertionend.
 9. The friction stabilizer according to claim 2 further comprisinganother extendable tab proximal the extendable tab and positioneddiametrically opposite the tube gap space.
 10. The friction stabilizeraccording to claim 4 wherein the extendable tab has a rectangular shape.11. The friction stabilizer according to claim 4 wherein the extendabletab has a triangular shaped tab.
 12. The friction stabilizer accordingto claim 4 wherein the extendable tab has a polygonal shape.
 13. Thefriction stabilizer according to claim 4 wherein the tab has a curvedshape.
 14. A method of making a friction stabilizer for installation ina structural body, the method comprising the steps of: providing a coilof metal and unrolling the coil of metal into a strip, pressing theshape of an extendable tab to be formed into the strip of metal suchthat the extendable tab is joined to the strip of metal with a joiningportion, moving the strip of metal through cold rolling dies and rollforming the strip of steel into a tubular body having a tube gap spacewith an exterior surface such that the extendable tab is diametricallyopposite the tube gap space.
 15. The method according to claim 14further including: roll forming the strip to have a first portion withan impact end, a second portion with an insertion end, and a bentportion that joins the first and second portions and forming theextendable tab in the first portion proximal the bent portion.
 16. Themethod according to claim 15 further comprising: forming the firstportion such that the extendable tab is elevated a minimal amountrelative to the surrounding exterior surface.
 17. The method accordingto claim 16 wherein the step of pressing the shape of the extendable tabinto the strip of metal such that the extendable tab extends in adirection toward the impact end and away from the insertion end of thetubular body.
 18. The method according to claim 15 further comprising:forming the first portion with an opening such that the extendable tabis partly positioned in the opening.
 19. The method according to claim15 further comprising aligning a weld ring having a weld ring gap spacewith the impact end such that the weld ring gap space is diametricallyopposite the tube gap space and welding the weld ring to the impact end.20. A method of supporting a mine having at least one drilled bore fromcaving-in, the method comprising the steps of: providing a frictionstabilizer having a tubular body with a tube gap space such that thetubular body is capable of moving between an uncompressed position and acompressed position, providing the tubular body with a first portionhaving an impact end and a second portion having a taper and joining thefirst and second portions with a bent portion, providing the firstportion with an impact end and the second portion with an insertion endand providing the tubular body with a tube gap space, providing thetubular body with an exterior surface and providing the first portionwith an opening proximal the bent portion, providing a joining portionand joining an extendable tab to the first portion such that theextendable tab is proximal the bent portion and partly positioned in theopening, with the extendable tab extending in a direction toward theimpact end and elevated a minimal amount relative to the exteriorsurface of the tubular body when the tubular body is in the uncompressedposition and wherein the extendable tab is diametrically opposite thetube gap space, aligning the impact end of the tubular body with thedrilled bore and hammering the impact end of the tubular body anddriving the tubular body into the drilled bore such that the tubularbody compresses radially inward and moves from the uncompressed positionto the compressed position such the extendable tab moves out of theopening and engages the drilled bore to support axial loads impartedthereon by the mine.